Battery connect/disconnect for an uninterruptible power supply

ABSTRACT

An uninterruptible power supply (UPS) is provided that can alleviate difficulties in shipping electronic devices containing batteries, such as UPS devices by providing a battery connect/disconnect assembly that can connect and disconnect an internal battery from outside the chassis of the UPS. The UPS comprises an input, output, DC voltage source, electrical circuit, chassis, and connect/disconnect assembly. The input receives input power from an input power source, and the output provides output power to a load. The DC voltage source provides DC power and has first and second terminals. The electrical circuit is operably coupled to the DC voltage source and is capable of receiving the input power and providing the output power. The chassis houses at least the DC voltage source and the electrical circuit. The connect/disconnect assembly is operably coupled to the DC voltage source and is constructed and arranged to be operable from outside the chassis. The connect/disconnect assembly has a first state wherein the DC voltage source is operably coupled to the electrical circuit and a second state wherein the DC voltage source is operably disconnected from the electrical circuit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit, and is a continuation applicationof prior U.S. application Ser. No. 10/137,202 filed Apr. 30, 2002 nowU.S. Pat. No. 7,057,308, entitled “Battery Connect/Disconnect forUninterruptible Power Supply,” which is hereby incorporated by referencein its entirety.

FIELD OF THE INVENTION

Embodiments of the invention are directed towards a battery connect usedwith an electronic device having an internal energy source such as abattery, particularly an electronic device such as an uninterruptiblepower supply (UPS). More particularly, embodiments of the presentinvention are directed towards a UPS that complies with domestic andinternational shipping air regulations relating to battery disconnectduring air shipment of an electronic device having a battery.

BACKGROUND OF THE INVENTION

An uninterruptible power supply (UPS) is a type of power supply used topower and protect an electrical load that is sensitive to fluctuationsin or the absence of electrical power. The UPS can be connected betweenthe load and a source of electrical power, such as a mains power sourceor other commercially provided electric power. The UPS uses commerciallysupplied AC power to charge a DC battery and provide the AC power toload. Upon outages of power, the load draws its AC power from the DCbattery typically through a DC to AC inverter. This isolates the loadfrom power surges or brownouts and also furnishes a source of powerduring brief outages.

Commonly, a UPS comprises a rectifier, inverter, battery charger, DCbattery, and other components, all housed within a single case orpackage. FIG. 1 shows a typical prior art UPS 1 used to provideregulated uninterrupted power. The UPS 1 includes an input filter/surgeprotector 2, a transfer switch 3, a controller 4, a battery 5, a batterycharger 6, an inverter 7, and a DC-DC converter 8. The UPS also includesan input 9 for coupling to an AC power source and an outlet 10 forcoupling to a load.

The UPS 1 operates as follows. The filter/surge protector 2 receivesinput AC power from the AC power source through the input 9, filters theinput AC power and provides filtered AC power to the transfer switch 3and the battery charger 6. The transfer switch 3 receives the AC powerfrom the filter/surge protector 2 and also receives AC power from theinverter 7. The controller 4 determines whether the AC power availablefrom the filter/surge protector is within predetermined tolerances, andif so, controls the transfer switch to provide the AC power from thefilter/surge protector to the outlet 10. If the AC power from therectifier is not within the predetermined tolerances, which may occurbecause of “brown out,” “high line,” or “black out” conditions, or dueto power surges, then the controller 4 controls the transfer switch 3 toprovide the AC power from the inverter 7. The DC-DC converter 8 is anoptional component that converts the output of the battery 5 to avoltage that is compatible with the inverter 7. Depending on theparticular inverter 7 and battery 5 used the inverter 7 may beoperatively coupled to the battery 5 either directly or through a DC-DCconverter 8.

Electrical devices having installed batteries, such as UPS's have thepotential to cause safety problems, even when the electrical device isnot operating. For example, short circuits can occur in electricaldevices during transport. These short circuits can present a firehazard.

Another problem that can occur is where a component in circuitryconnected to a battery during shipping develops a fault that causes itto generate heat. An example is a printed wiring board or electroniccapacitor electrically connected to a battery during shipping, which candevelop an internal fault through contamination, defect, or dendriticgrowth. Such conditions may result in the release of battery energy andmay not cause protective fusing to actuate but have been know to giverise to high temperature and initiate afire. Moreover, the subsequentfeeding of the fire by electrical energy of the battery may causenormally non-combustible materials such as printed wiring assemblies toburn.

Yet another concern is that electrical devices with installed batteriesmay pose risks other than those associated with the “chemical” hazard ofelectrolyte or other battery components, or the risk of short circuit.One important concern in this regard is the risk arising from thepossible generation of a dangerous quantity of heat owing to theunintentional and uncontrolled release of energy stored within abattery. Heat evolution associated with such an energy release canaffect the device itself, packaging materials or other adjacent cargo insuch a way as to initiate fire, and/or generate smoke. Even without ashort circuit condition existing, an unacceptable situation may arisewhen a component in circuitry connected to a battery becomes heated to apoint where combustion is initiated in the component itself, or innearby materials, including packaging materials.

In response to these concerns, organizations such as the United StatesDepartment of Transportation (USDOT), and the International AirTransport Association (IATA) have established regulations relating tothe shipment of electrical batteries and battery-powered devices (see,e.g., IATA Regulations Special Provision A123 and USDOT Research andSpecial Programs Administration Notice No. 99). These regulationsprovide that electrical batteries and battery-powered devices must havetheir batteries protected from short circuits and/or insulated duringtransport. Because the batteries of many electrical devices are locatedinside the chassis of the devices, compliance with these regulations canbe difficult, time-consuming, and error-prone.

SUMMARY OF THE INVENTION

One embodiment of the invention alleviates the aforementioneddifficulties in shipping electronic devices containing batteries, suchas UPS devices by providing a battery connect that can connect anddisconnect an internal battery from outside the chassis of theelectronic device.

In one embodiment, the invention provides an uninterruptible powersupply (UPS) that provides power to a load, the UPS comprising an input,output, DC voltage source, electrical circuit, chassis, andconnect/disconnect assembly. The input receives input power from aninput power source, and the output provides output power to a load. TheDC voltage source provides DC power and has first and second terminals.The electrical circuit is operably coupled to the DC voltage source andis capable of receiving the input power and providing the output power.The chassis houses at least the DC voltage source and the electricalcircuit. The connect/disconnect assembly is operably coupled to the DCvoltage source and is constructed and arranged to be operable fromoutside the chassis. The connect/disconnect assembly has a first statewherein the DC voltage source is operably coupled to the electricalcircuit and a second state wherein the DC voltage source operablydisconnected from the electrical circuit.

In at least one embodiment, the connect/disconnect assembly comprisesfirst and second connect/disconnect terminals and a shunt. The firstconnect/disconnect terminal is operably connected to the electricalcircuit. The second connect/disconnect terminal is operably connected tothe second terminal of the DC voltage source and is electricallyisolated from the first connect disconnect/terminal when theconnect/disconnect assembly is in the second state. The shunt comprisesan electrically conductive material and has a first position and asecond position. In the first position, the shunt is operable to make anelectrical connection between the first and second connect/disconnectterminals. In the second position, the shunt does not make an electricalconnection between the first and second connect/disconnect terminals.

In some embodiments, the shunt may be disposed within a first insulatingstructure. In some embodiments, either or both of the first and secondconnect/disconnect terminals are disposed within a second insulatingstructure. In some embodiments the first and second insulatingstructures are constructed and arranged to mate with each other.

In one embodiment, the connect/disconnect assembly comprises a housingand a plug. The housing is sized to attach to a respective housingopening on the chassis and is constructed and arranged to hold a firstterminal operably connected to the electrical circuit and a secondterminal operably connected to the DC voltage source. The plug isconstructed and arranged to mate with the housing and has a conductorcapable of making an electrical connection between the first terminal ofthe housing and the second terminal of the housing when the plug ismated to the housing. In the first state the plug is connected to thehousing, and in the second state the plug is disconnected from thehousing.

Either or both of the first and second terminals can be attached to thehousing and/or formed within the housing. Either or both of the housingand plug can comprise a dielectric.

In one embodiment, the invention provides an uninterruptible powersupply (UPS) that provides power to a load, comprising an input, anoutput, a DC voltage source, an electrical circuit, and means foroperably connecting a second terminal of the DC voltage source to theelectrical circuit and disconnecting a second terminal of the DC voltagesource from the electrical circuit. The input receives power from aninput power source, and the output provides output power to a load. TheDC voltage source provides DC power and has first and second terminals.The electrical circuit is operably coupled to the DC voltage source andis capable of receiving the input power and providing the output power.The chassis houses at least the DC voltage source and the electricalcircuit.

In some embodiments, at least a portion of the means for operablyconnecting and disconnecting is located outside the chassis. In at leastone embodiment, at least a portion of the means for operably connectingand disconnecting is located on the chassis. In some embodiments, themeans for operably connecting and disconnecting is entirely or at leastpartially operable from outside the chassis.

In another embodiment, the invention provides, for a UPS containedwithin a chassis, the UPS comprising a DC voltage source having firstand second source terminals and an electrical circuit having first andsecond circuit terminals that receive energy from the DC voltage source,a method of connecting and disconnecting a DC voltage source from theelectrical circuit from outside the chassis. The first source terminalis coupled to a first receptacle terminal in a receptacle attached tothe chassis, the receptacle having a first receptacle terminal and asecond receptacle terminal, each receptacle terminal being accessiblefrom outside the chassis. The receptacle in at least one embodiment maycomprise at least in part an insulating material. The first circuitterminal is coupled to the second receptacle terminal. The second sourceterminal is coupled to the second circuit terminal. The first receptacleterminal is isolated from the second receptacle terminal, such that theDC voltage source is disconnected from the electrical circuit when thefirst receptacle terminal is isolated from the second receptacleterminal.

The first receptacle terminal can be coupled to the second receptacleterminal by providing a conductor located external to the chassis, theconductor constructed and arranged to electrically couple the firstreceptacle terminal to the second receptacle terminal, such that the DCvoltage source is connected to the electrical circuit when the firstreceptacle terminal is coupled to the second receptacle terminal.

The conductor can be installed in a second structure formed at least inpart from electrically insulating material, the second structureconstructed and arranged to mate with the first structure. The firststructure can be connected to the second structure by installing atether to one of the first and second structures, the tether constructedand arranged to attach to the other of the first and second structureswhen the first and second structures are installed to the chassis.

The foregoing and other objects, aspects, features, and advantages ofthe present invention will become more apparent from the followingdetailed description of the invention when viewed in conjunction withthe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

An understanding of the principles of the invention may be readilyattained by reference to the following specification and theaccompanying drawings in which:

FIG. 1 is a block diagram of a typical uninterruptible power supply;

FIG. 2 is a battery connection schematic, in accordance with anembodiment of the invention;

FIG. 3 is an illustration showing the placement of a batteryconnect/disconnect assembly into the rear panel of a first UPS, inaccordance with one embodiment of the invention;

FIG. 4 is a perspective illustration of the battery connect/disconnectassembly of FIG. 3;

FIG. 5 is an illustration showing a battery connect plug of the batteryconnect/disconnect assembly fully connected to the battery connecthousing, in accordance with one embodiment of the invention;

FIG. 6 is a perspective view of the illustration of FIG. 6;

FIG. 7 is an illustration showing the rear panel of a UPS with thebattery connect plug installed in an opening for receiving the batteryconnect housing, in accordance with one embodiment of the invention;

FIG. 8 is a right perspective view of a battery connect housing, inaccordance with one embodiment of the invention;

FIG. 9 is a view of the battery connect housing of FIG. 8, taken fromthe top;

FIG. 10 is a view of the battery connect housing of FIG. 8, taken fromthe bottom;

FIG. 11 is a front view of the battery connect housing of FIG. 8;

FIG. 12 is a rear view of the battery connect housing of FIG. 8;

FIG. 13 is a partial right cross sectional view of the battery connecthousing of FIG. 8, showing a wire assembly and terminal insert;

FIG. 14 is a perspective view of the battery connect plug, in accordancewith one embodiment of the invention;

FIG. 15 is left cross-sectional view of the battery connect plug of FIG.15, taken along the C-C line;

FIG. 16 is a perspective view of the blades of the battery connect plugof FIG. 15;

FIG. 17 is a view of the blades of the battery connect plug of FIG. 16as seen from the direction of the F arrow in FIG. 16; and

FIG. 18 is a cross sectional view showing how the shunt attaches to thebattery connect plug 70 of FIG. 16.

The drawings are not necessarily to scale, emphasis instead generallybeing placed upon illustrating the principles of the invention.

DETAILED DESCRIPTION

Embodiments of the invention permit an energy storage device or powersource located within an electrical device (e.g., located within achassis) to be disconnected from and reconnected to other equipmentwithin the chassis, without having to open the chassis. The ability todisconnect and reconnect internal energy storage devices as needed mayprovide improved energy storage performance (e.g., longer battery life)and enables the electrical device to meet shipping regulations.

For example, one embodiment of the invention is used to disconnect andreconnect a battery 5 in the UPS device 1 illustrated in FIG. 1, from atleast one other component that obtains energy from the battery, such asthe inverter 7, or any on or more electrical circuits in the UPS. In atleast one embodiment of the invention, the disconnection is done using abattery connect/disconnect assembly (described further herein), which isaccessible to a user without requiring the user to directly contact thebattery 5, such as by opening the chassis, housing, or other enclosurethat contains the UPS device. In one embodiment, the batteryconnect/disconnect assembly is constructed and arranged to be operablycoupled from outside the electronic device through the exterior (e.g.,the chassis or enclosure) of the electronic device to the interior ofthe electronic device, so that the connect/disconnect operation may beperformed manually, from a location accessible on or outside of thechassis or housing of the electronic device.

Embodiments of the invention will now be described. Although theembodiments are described in connection with the disconnection andreconnection of a battery in an uninterruptible power supply (UPS),those skilled in the art will appreciate that the invention hasapplicability in other types of electronic devices, including virtuallyany electrical/electronic device or electrical/electronic equipmenthaving an energy storage device (e.g., a battery, capacitor, and thelike) contained therein.

FIG. 2 is a simplified block diagram schematic of a UPS 1 implementingan embodiment of the invention and showing the UPS 1 with a batteryconnect/disconnect assembly 50. The remainder of the UPS 1 may besimilar to the UPS topology shown in the UPS 1 of FIG. 1, but also couldhave a different topology. The battery connect/disconnect assembly 50provides a connect/disconnect feature for one terminal of the battery 5.The battery connect/disconnect assembly 50 comprises a housing 60 and aplug 70 that is constructed and arranged to mate with the housing 60.The housing 60 includes a first housing terminal 35 (also referred toherein as a “first battery connect/disconnect terminal”) and a secondhousing terminal 40 (also referred to herein as a “second batteryconnect/disconnect terminal”). The plug 70 includes a shunt 100 that,when the plug 70 is mated to the housing 60, provides a short circuitbetween the first housing terminal 35 and the second housing terminal 40in the housing 60. The appearance and construction of the batteryconnect housing are explained more fully in FIGS. 3-18 herein.

In the embodiment illustrated in FIG. 2, the battery connect/disconnectassembly 50 is disposed at the rear panel 90 of the chassis for the UPS1, but that location is not limiting. The battery connect/disconnectassembly 50 can be located anywhere where it can be accessible to a userfor connection and disconnection. Advantageously, the batteryconnect/disconnect assembly 50 is positioned so that it is easilyviewable by a user to determine whether or not the batteryconnect/disconnect assembly is connected. In addition, in one embodimentthe battery connect/disconnect assembly 50 is located so that it isaccessible to a user during “set up” of the UPS 1, but is not positionedwhere the battery connect/disconnect assembly 50 might accidentallybecome disconnected during operation of the UPS 1. This location mayvary depending on how the UPS 1 is oriented during operation and duringtransport. In some embodiments, it may be preferable to locate thebattery connect/disconnect assembly on the top or front portion of achassis, for example. In another example, the battery connect/disconnectassembly 50 may be positioned within an integrated compartment on thechassis of the UPS, which compartment may also have a cover or door foreasy access (advantageously without tools) and/or viewing of the batteryconnect/disconnect assembly 50.

In FIG. 2, a first battery terminal 15 of the battery 5 (shown forillustrative purposes only as the positive terminal) is operably coupledto a first printed circuit board (PCB) terminal 25 on the PCB 10 thatcontains the electronic components of the UPS 1. A second PCB terminal30 has a polarity opposite to that of the first PCB terminal 25. The PCB10 is operably coupled via the second PCB terminal 30 to a first batteryconnect/disconnect terminal 35 of the battery connect/disconnectassembly 50. A second battery terminal 20 (which has a polarity oppositeto that of the first battery terminal 15) is operably coupled to asecond battery connect/disconnect terminal 40. In the embodiment shownin FIG. 2, first and second high power connectors 80 (such as thoseavailable from Anderson Power Products of Sterling, Mass.) areillustrated as part of the connections between the battery 5 and theother elements to which the battery is connected 5, but these additionalconnectors are not required in all embodiments of the invention.Incorporating additional connectors such as the high power connectors 80may simplify the overall manufacture of the UPS 1.

Note that some embodiments of the invention can be implemented such thatthe polarities are the reverse of those shown in FIG. 2, as thoseskilled in the art will appreciate.

Referring again to FIG. 2, it can be seen that the first batteryconnect/disconnect terminal 35 and the second battery connect/disconnectterminal 40 are at the same polarity (which is shown for illustrativepurposes only as negative polarity) and are connectable to form a shortcircuit that will connect the second battery terminal 20 to the secondPCB terminal 30. This short circuit is provided by the shunt 100 in theplug 70. The battery connect/disconnect assembly 50, when in the“connected” state, thus operably connects the first batteryconnect/disconnect terminal 35 to the second battery connect/disconnectterminal 40 via the shunt 100 disposed in the plug 70, thereby operablyconnecting the battery 5 to the PCB 10, and permitting the UPS 1 tooperate. When in the “disconnected” state (i.e., when the shunt 100 isnot operably inserted to a degree sufficient to couple together thefirst and second housing terminals 35, 40), however, the batteryconnect/disconnect assembly 50 “breaks” the connection between bothterminals of the battery 5 and the PCB 10, preventing electricalcircuits on the PCB 10 from being energized.

In FIG. 2, the DC-AC converter 8, inverter 7, transfer switch 3, andcontrol 4 are shown by way of illustration only as being disposed on asingle PCB 10, to which energy from the battery 5 is routed. Of course,any one or more of the electrical components (DC-AC converter 8,inverter 7, transfer switch 3, and control 4) may be located on one ormore other PCB's, or located by themselves. Moreover, the PCB 10 mayinclude other or different circuits and/or components. For example, ifthe invention is used with an electronic device other than a UPS, thePCB 10 may comprise many different types of circuits. In addition, thoseskilled in the art will appreciate that the connections between thebattery 5, PCB 10, and battery connect/disconnect assembly 50 mayreadily be adapted to multiple PCB's 10 and/or multiple batteries 5.These connections may also be adapted for multiple batteryconnect/disconnect assemblies 50.

FIGS. 3 and 4 are illustrations of a front and perspective view,respectively, showing the arrangement of an embodiment of the batteryconnect/disconnect assembly 50 into the rear panel 90 of a first UPS 1,in accordance with one embodiment of the invention (the rear panel 90shown in FIGS. 3 and 4 is provided for illustrative purposes only and isnot limiting). In FIGS. 3 and 4, the battery connect/disconnect assembly50 is in a “disconnected” state. As FIGS. 3 and 4 illustrate, the plug70 and housing 60 of one embodiment have the shape of an equilateraltriangle with rounded edges. The rounded triangular shape may help tominimize mounting space while maintaining ease of installation; however,in other embodiments virtually any shape of battery connect/disconnecthousing 50 is usable.

Referring again to FIGS. 3 and 4, the battery connect/disconnect housing50 includes a tether 110 that connects the plug 70 to the housing 60 toprevent loss of the plug 70. The tether 110 is sized to maintainorientation of the plug and to prevent the blades of the shunt 100 frombeing accidentally inserted into another opening on the panel, such asan AC output. The limited length of the tether 110, in one embodiment,also can help prevent the shunt 100 from accidentally short circuitingother UPS outputs or inputs. Similarly, in one embodiment, the tether110 has a width wide enough to prevent rotation of the plug 70, to helpprevent inadvertent short circuiting (e.g., accidentally having one ofthe blades of the shunt 100 contact a “live” UPS terminal (e.g., an ACoutput terminal) while the other blade contacts the chassis) to otherUPS inputs and/or outputs. Tethering the plug 70 to the housing 60 alsomakes it easier for the user to be reminded that the plug 70 must beconnected. As illustrated further herein in FIG. 7, the tether 110 isattached to the rear panel 90 and is “locked” in place when the housing70 is installed, thereby locking both the plug 70 and the housing 60 inplace without fasteners, saving assembly time and cost.

The shunt 100 of the plug 70 comprises a pair of angled blades that aremade of a conductive material and joined within the plug 70. When theplug 70 is inserted into the housing 60, the blades of the shunt 100enter blade openings 115 in the housing 60 to contact the first andsecond housing terminals 35, 40 (these features are illustrated ingreater detail herein).

In the embodiment illustrated in FIGS. 3 and 4, the action mating theplug 70 to the housing may be as familiar to a user as plugging aconventional plug into a wall socket. Further, in at least oneembodiment, the blade openings 115 in the housing 60 that receive theblades of the shunt 100 are configured (e.g., angled) so that it is verydifficult for a user to “accidentally” insert an incorrect plug (e.g., aconventional plug) into the housing 60. Similarly, it will be difficultfor a user to accidentally insert the blades of the shunt 100 into areceptacle, such as a wall outlet or the AC receptacles 120 on thechassis of the UPS 1.

FIGS. 5 and 6 are front and perspective views, respectively, of thebattery connect/disconnect assembly 50 in a “connected” state. In theconnected state, the blades of the shunt 100 are inserted into thehousing 60 far enough to contact the first and second housing terminals35, 40 and form a short circuit between them.

In at least one embodiment, the battery connect/disconnect assembly 50snaps into the chassis of the UPS 1 and as a result does not require anyfasteners, which saves assembly time and material cost. FIG. 7 is anillustration showing the rear panel of a UPS with an embodiment of theplug 70 installed in an opening 120 formed in the rear panel 90 of thechassis of the UPS 1. The tether 110 of the plug 70 includes protrusions125 that are constructed and arranged to hold the plug 70 within theopening 20. The opening 120 is formed to mate with the shape andbuilt-in connectors of the housing 60, and includes a key portion 129and interlocking portions 127, which mate with respective features onthe housing 60 (described in connection with FIG. 8). These featuresenable the housing 60 and plug 70 to be installed without additionalfasteners. The particular shapes and orientations for the opening 120,housing 60, and plug 70 are provided by way of example only and are notlimiting. Many other shapes of battery connect/disconnect assembly 50and associated opening 120 (e.g., oval, circular, square, trapezoidal,irregular, etc.) are usable in accordance with the invention.

FIGS. 8, 9, and 10 are right perspective, top, and bottom views of thehousing 60 of a battery connect/disconnect assembly 50, in accordancewith one embodiment of the invention. FIG. 11 is described furtherbelow. FIGS. 12 and 13 are front and back views, respectively, of the ofthe housing 60 of the battery connect/disconnect assembly 50 of FIG. 8.The housing 60 is a structure formed from an electrically insulatingmaterial and holds first and second housing terminals 35, 40. In oneembodiment, the housing 60 may be formed in a manner similar to aconventional electrical receptacle used to receive the prongs of a plug.The housing 60 includes a key 135 constructed and arranged to mate withthe key portion 129 of the opening 120. The key 135 can improve ease ofassembly. The housing 60 also includes three claws 130, which mate withthe respective interlocking portions 127 in the opening 120. Thus, thehousing 60 can “snap” into the opening 60 and be held in place withoutadditional fasteners. The blade openings 115, formed in the housing 60are constructed and arranged to receive the blades of the shunt 100 ofthe plug 70. The front portion 135 of the housing 60 acts as a shieldagainst electrical arcing and accidental short circuits.

FIG. 11 is a partial right cross sectional view of the battery connecthousing 60 of FIG. 8, showing connection of the first housing terminal35 to the housing 60. Those skilled in the art will appreciated thatshowing the first housing terminal 35 as being on the right side of thehousing 60 is provided by way of example only; in this embodiment, it isimmaterial where on the housing the first housing terminal 35 islocated, so long as the first housing terminal 35 is capable of matingto one of the blades of the shunt 100.

In one embodiment of the invention, the terminal 35 of the housing 60 isprovided by inserting a wire assembly 140 having a terminal attached toone end into the rear side of the blade openings 115 in the housing 60.The wire assembly 140 connects the terminal 35 to the second PCBterminal 30 (FIG. 2). In one embodiment, the first housing terminal 35is a push-on type terminal, such as a FASTON brand terminal, availablefrom TYCO Electronics/AMP, of Exeter N.H. In FIG. 12, a projecting,flexible claw 145 contacts an opening formed in the terminal 35. Whenthe terminal 35 (and wire assembly 140) is inserted into rear side ofthe blade opening 115 of the housing 60, the flexible claw 145 isdeflected as the terminal 35 (e.g., the FASTON terminal) is installed.When the terminal 35 is fully located, the flexible claw 145 springsback into its original position behind the terminal 35 and locks theterminal 35 into the housing 60 and prevents withdrawal of the terminal35.

Providing the first housing terminal 35 as a terminal at the end of awire assembly that snaps into the housing 60 can help to simply assemblyof the UPS 1; however, those skilled in the art will appreciate thatthere are many ways to provide a first housing terminal 35 (as well as asecond housing terminal 45) in the housing 60 where the respectiveterminal is operably coupled to either the PCB 10 or the battery 5. Forexample, a terminal capable of receiving the blade of the shunt 100 mayfirst be attached to the blade opening 115 in the housing 60 and thewire assembly 140 could be soldered, crimped, or otherwise attached tothe terminal. In another embodiment, the blade opening 115 can be linedwith a conductive material to form a terminal to which the wire assembly140 can be operably coupled. Those skilled in the art will appreciatethat many other configurations of wire and terminal are usable inaccordance with the invention.

FIGS. 14 and 15 are perspective and cross-sectional views of the plug70, in accordance with one embodiment of the invention. Thecross-sectional view of FIG. 15 is taken along the C-C line of FIG. 14.The plug 70 and tether 110, in one embodiment, are fixedly attached. Theplug 70 incorporates gripping features 140 to make it easier for a userto remove the plug 70 from the housing 60. In addition, the plug 70includes internal partitions 145 that are constructed and arranged tohold the shunt 100 in place and to work with features provided on theshunt 100 (described herein) to prevent the shunt 100 from becomingdislodged during connection and/or disconnection of the plug 70 to thehousing 60. The plug 70 forms an electrically insulating structurearound the shunt 100.

The shunt 100 has a pair of blades that mate to the blade openings 115in the housing 60. In one embodiment, the shunt is formed from a singlepiece of conductive material that is angled and cut to form blades.FIGS. 16, 17, and 18 are views of one embodiment of the shunt 100. FIG.16 is a perspective view of the shunt 100, FIG. 17 is a view of theshunt, as seen from the direction of the F arrow in FIG. 16, and FIG. 18is a cross sectional view showing how the shunt 100 attaches to the plug70. Referring to FIGS. 16-18, each blade of the shunt 100 includesserrations 150 that provide an interference fit between the shunt 100and the plug 70. The angling of the serrations help to lock the shunt100 into the plug 70 during assembly and to further “lock” the shunt 100during use, so that the shunt 100 is not dislodged during use. Inaddition, the shunt 100 includes a shunt claw 160 that also mates to aportion of the plug 70 to help lock the shunt 100 to the plug 70. Thus,the pair of serrations 150 and the shunt claw 160 provide a three-pointpress fit in to the plug 70.

The shunt 100 may be formed from any material capable of electricallyconnecting the first housing terminal 35 and the second housing terminal40 when the plug 70 is inserted into the housing 60. Usable materialsinclude, for example, conductive materials such as brass, silver, gold,copper, and materials plated with brass, silver, gold, copper, or othergood conductors.

Although the illustrated embodiment of the plug 70 and housing 60 showsthe shunt 100 as being a single conductor having a pair of “plug-like”blades mating to the blade openings 115 in the housing 60, the inventionis not limited to this configuration. In one example, the shunt 100 cancomprise a conductor, such as a piece of wire having appropriateterminals attached to each end, seated into a respective opening formedin the plug 70, which opening fixedly secures the shunt 100 in placeduring use. In another example, in one embodiment the housing terminals35, 40 may be disposed close enough together to receive a shunt 100having a single blade or conductor that is capable of electricallyconnecting the first and second housing terminals 35, 40. Further, thehousing 60 in one embodiment may comprise a plurality of pairs of firstand second housing terminals 35, 40 that are constructed and arranged tomate with a plurality of pairs of respective shunts 100 in a respectiveplug 70. Such an arrangement of multiple shunts and terminal pairs maybe applicable in UPS devices having more than one battery and/or whichhave high current outputs.

Except for the conductive portions (i.e., at least the first and secondhousing terminals 35, 40, and the shunt 100), the housing 60, plug 70,and tether 110 of the battery connect/disconnect assembly 50, in oneembodiment, can be formed from virtually any material capable of beingformed into the desired shape. In one embodiment, the housing and theplug are formed from material capable of providing insulation againstthe current levels and/or heat generated in the UPS 1. For example, thehousing, plug, and/or tether in some embodiments can be made usingnon-conductive material (e.g., a dielectric). Illustrative examples ofusable materials include, nylon, engineering plastics, ceramics,synthetic rubber, composites, etc. For example, in one embodiment, thehousing and plug are formed from a plastic (e.g., a thermoplastic)meeting a fire rating standard such the Underwriters Laboratories (UL)fire rating as 94V-0 and/or 94-5V and having a relative temperatureindex (RTI) of at least 85 degrees Celsius, with and without impact.Those skilled in the art will appreciate that many theconnect/disconnect assembly may be made from any materials meetingregulatory and operational requirements for the electronic device.

In some embodiments, the housing, plug, and/or tether may be formed froma conductive material, but also have non-conductive portions. Forexample, in some embodiments, the housing, plug, or tether may be formedfrom a conductive and/or metallic material, such as copper, aluminum, orsteel, that is partially or entirely coated, covered, or lined with adielectric or another insulating material, such as TEFLON or plastic.Similarly, in some embodiments the shunt 100 can comprise bothconductive and non-conductive portions, so long as the shunt 100 is ableto operably couple the first and second housing terminals 34, 40 whenthe battery connect/disconnect assembly 50 is in the “connected” state”.For example, in one embodiment a shunt 100 may be made using a piece ofTEFLON coated wire having lugs, terminals, or blades attached to eitherend, with the plug 70 having recesses formed therein to receive andsecure the shunt 100. Those skilled in the art will appreciate thatvirtually any combination of conductive and non-conductive materials isusable for the various parts of the battery connect/disconnect assembly50 so long as the battery connect/disconnect assembly 50 can reliablyand safely maintain the “connected” and “disconnected” states describedherein.

At least one embodiment of the invention provides a UPS that is incompliance with the USDOT's Hazardous Materials Regulations and IATAregulations for battery disconnect and disconnect of energy storingdevices during shipment. Using at least some embodiments of theinvention, an end user is able to connect and disconnect the energystorage device of an electrical device from outside the chassis of theelectrical device. In contrast, in some existing electronic devices, theuser must open the battery compartment and physically connect anddisconnect the battery (or other energy storage device). In at leastsome embodiments of the invention, however, whenever it isdesired/required that the electronic device have its energy storagedevice be disconnected (such as during shipping or transport of theelectronic device), the plug 70 is removed from the housing 60, therebydisconnecting the battery or other energy storage device from theinternal electronics within the electronic device, and helping to reduceand/or eliminate the risk of electrical energy contributing to a firecaused by a short circuit or other fault in the electronics. In at leastsome embodiments of the invention, when the battery connect/disconnectis in the “disconnected” state, the plug 70 and/or the tether 110 can bephysically secured to the chassis of the UPS 1, such as by a piece oftape, a tie wrap, a connector built-into the chassis, and the like, tofurther ensure that the battery connect/disconnect assembly remains inthe “disconnected” state even when vibrations, bouncing, etc., occur.

Further, the design of the battery connect/disconnect of at least someembodiments of the invention makes it extremely unlikely that thebattery connect/disconnect assembly could accidentally become“connected” during transport. This mechanical disconnect feature of atleast some embodiments of the invention can be more advantageous andreliable than disconnecting the battery via an external switch, becausethere is the chance that the switch can unexpectedly switch to aconnected state, with or without external vibrations, impacts, orcontact. Moreover, the nature of the battery connect/disconnect assemblyshown in at least some embodiments of the invention enablesmanufacturers and users to quickly and easily determine, by looking atthe outside of the UPS 1, that the UPS is in a disconnected state.

Embodiments of the invention may provide several additional advantages.For example, the battery connect/disconnect assembly 50 in at least someembodiments has a configuration that has reduced mounting space andrequire minimal raw material for manufacture. In addition, the threepoint snap feature provided in one embodiment is relatively simple toassemble and may be easier to assemble than other known connectorsbecause few, if any, fasteners are required. In one embodiment, nofasteners are required to assembly both the plug 70 and the housing 60to the chassis of the electronic device. Having a snap fit may alsominimizes the risk of an end user inadvertently removing the housingfrom the panel.

Although at least some of the embodiments described herein can bemanufactured from a moldable material, such as a synthetic material, ina single forming step (e.g., injection molding) it should be understoodthat the battery connect/disconnect design in accordance with theprinciples of the invention could also be achieved by othermanufacturing techniques capable of producing the respective parts ofthe battery connect/disconnect assembly 50 effectively, in a quick,simple, low-cost, or otherwise improved manner. For example, the batteryconnect/disconnect assembly 50 could be formed by milling, punching,filing, or cutting one or more of the respective parts of the batteryconnect/disconnect out of a solid material, such as a solid plasticmaterial. It also should be understood that the batteryconnect/disconnect assembly 50 could be made using materials ofbiological or metallic origin that possess the desired mechanical andconductive or non-conductive qualities required for the respective part.Details of the above-described materials and the manufacturing methodsare well known to those skilled in the plastics and materials arts andneed not be disclosed herein in detail.

Further, although some embodiments of the invention have been describedin connection with a UPS having an AC input and an AC output, theinvention is not limited to any particular UPS topology. As thoseskilled in the art will recognize, the battery connect/disconnectassembly 50 of the invention can be used with UPS devices having one ormore DC outputs, one or more AC outputs, one or more DC inputs, one ormore AC inputs, and combinations of AC and DC outputs and inputs.Moreover, the invention is not limited to UPS devices and is usable withdevices other than UPS devices. Many other articles of manufacture,including automobiles, power supplies, computers, consumer electronicdevices, medical devices, power generation systems, etc., may includeenergy storage devices such as batteries and/or capacitors. If it isdesired and/or required that the energy storage device of the respectivearticle of manufacture be disconnected and reconnected, for any reason,especially during transport, at least some embodiments of the inventionmay be useful to accomplish the connection and disconnection.

In describing the embodiments of the invention illustrated in thefigures, specific terminology is used for the sake of clarity. However,the invention is not limited to the specific terms so selected, and eachspecific term at least includes all technical and functional equivalentsthat operate in a similar manner to accomplish a similar purpose.

Having thus described at least one illustrative embodiment of theinvention, various alterations, modifications and improvements willreadily occur to those skilled in the art. Such alterations,modifications and improvements are intended to be within the scope andspirit of the invention. Accordingly, the foregoing description is byway of example only and is not intended as limiting.

Although the invention has been described and pictured in a preferredform with a certain degree of particularity, it is understood that thepresent disclosure of the preferred form, has been made only by way ofexample, and that numerous changes in the details of construction andcombination and arrangement of parts may be made without departing fromthe spirit and scope of the invention as hereinafter claimed.

1. An uninterruptible power supply (UPS) comprising: a housing; a powerinput configured to receive power from a power source; an internal powersource disposed in the housing; an electrical circuit disposed withinthe housing and configured to receive power from the power input and theinternal power source; a power output module coupled to the electricalcircuit and configured to receive power from the electrical circuit; aswitch connected to the housing and configured to be actuated fromoutside the housing, the switch comprising: a first portion includingfirst and second electrically isolated electrical contacts, the firstcontact being coupled to the internal power source and the secondcontact being coupled to the electrical circuit, wherein the firstportion includes an insulating structure that houses the first andsecond contacts; and a second portion tetheredly connected to thehousing and configured to mate to the first portion, the second portionbeing configured to electrically couple the first and second contactswhen the second portion is mated to the first portion, wherein thesecond portion includes an insulating structure that is configured tomate with the insulating structure of the first portion.
 2. The UPS ofclaim 1 wherein the second portion includes a shunt configured toelectrically couple the first and second contacts when the secondportion is mated to the first portion.
 3. The UPS of claim 2 wherein theshunt is solid brass, solid silver, solid gold, solid copper, brassplated, silver plated, gold plated, or copper plated.
 4. The UPS ofclaim 2 wherein the shunt is disposed within the insulating structure.5. The UPS of claim 2 wherein ends of the shunt protrude outwardly fromthe second portion.
 6. The UPS of claim 5 wherein the ends areconfigured in a non-conventional plug configuration.
 7. The UPS of claim5 wherein the ends are disposed in a V formation.
 8. The UPS of claim 1wherein the second portion is tetheredly coupled to the housing suchthat the second portion is biased against mating to the first portion.9. The UPS of claim 1 further comprising a connector, wherein the firstcontact is coupled to the internal power source via the connector. 10.The UPS of claim 1 wherein the first portion further includesprotrusions configured to connect the first portion to the housing. 11.The UPS of claim 1 wherein the first and second portions are configuredto mate in a male/female configuration.
 12. An uninterruptible powersupply (UPS), for use with a load, the UPS comprising: a housing; apower input configured to receive power from a power source; an internalpower source disposed in the housing; an electrical circuit disposedwithin the housing and configured to receive power from the power inputand the internal power source; a power outlet coupled to the electricalcircuit and configured to provide power to the load; a two-part switchconnected to the housing and configured to be actuated from outside thehousing, the switch comprising: a first portion including first andsecond electrically isolated electrical contacts, the first contactbeing coupled to the internal power source and the second contact beingcoupled to the electrical circuit, wherein the first portion includes aninsulating structure that houses the first and second contacts; a secondportion configured to mate to the first portion, the second portionbeing configured to electrically couple the first and second contactswhen the second portion is mated to the first portion, wherein thesecond portion includes an insulating structure that is configured tomate with the insulating structure of the first portion; and a tetherthat connects the second portion to the housing.
 13. The UPS of claim 12wherein the tether is configured to maintain an orientation of the firstportion relative to the second portion with the second portion separatedfrom the first portion.
 14. The UPS of claim 12 wherein the secondportion includes a shunt configured to electrically couple the first andsecond contacts when the second portion is mated to the first portion.15. The UPS of claim 14 wherein the shunt is solid brass, solid silver,solid gold, solid copper, brass plated, silver plated, gold plated, orcopper plated.
 16. The UPS of claim 14 wherein the shunt is disposedwithin the insulating structure.
 17. The UPS of claim 14 wherein ends ofthe shunt protrude outwardly from the second portion.
 18. The UPS ofclaim 17 wherein the ends are configured in a non-conventionalconfiguration.
 19. The UPS of claim 17 wherein the ends are disposed ina V formation.
 20. The UPS of claim 12 wherein the first portion furtherincludes protrusions configured to connect the first portion to thehousing.
 21. The UPS of claim 12 wherein the first and second portionsare configured to mate in a male/female configuration.
 22. The UPS ofclaim 12 wherein the tether is configured such that the second portionis inhibited from being inserted into the power outlet.